Location: Preston, Lancashire
Capacity: 90MW
Services: ICP, Principal Contractor, EPC, design, civil works, traffic management

Project details

With the cable route from outside the business park to the substation at over 1km long, and being the main feeder to the M6, the local highways team deemed this a highly traffic sensitive network and a critical emergency route in the event of any motorway congestion. Detailed discussions with local highways and businesses were required to ensure that traffic flow was maintained with any potential disruption minimised.

At the same time, and adjacent to the Gas Plant being constructed by Green Frog Connect, a 50MW Battery Energy Storage Plant was in development. In collaboration with this site, Green Frog Connect extended their contract to facilitate the off-site cable route for both developments which subsequently consisted of 4No 33kV circuits and corresponding pilot circuits. Working to extremely challenging timescales, an intricate program and complex traffic management plan was devised and agreed with all stakeholders. By operating continuous shift patterns, a 30% program improvement was achieved, enabling the successful energisation of the BESS site ahead of the Winter Triad trading period and ensuring essential balancing services to the National Grid during high usage periods, mitigating potential power outages.

On site as the Principal Contractor, Green Frog Connect provided full turnkey services for this gas project. Our scope of work included the design and construction of the balance of plant, including switchgear, transformers, power and control cabling for the client’s SCADA
system, security control systems and auxiliary power supplies, along with the design and construction of the civil works including ground works, reinforced concrete structures, fencing and access roads.

Following the successful sign off of the revised G99 commissioning procedure for the site’s 27 GE Jenbacher gas engines, the site was available for the client to trade and meet its Capacity Market obligations.

Our project management resulted in a 30% program improvement for the off-site grid connection cable works ensuring supplies were available ahead of the Winter Triad trading period.

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Location: Gateshead
Project length: Three months
Client: M. H. Southern & Company
Services: Independent Connection Provider (ICP)

As an Independent Connection Provider (ICP) we were able to go out to market to negotiate a significant cost saving from the client’s incumbent Distribution Network Operator (DNO) enabling a 25% reduction in grid connection costs.

Project details

Redeveloping and enlarging an existing site provided an opportunity for M. H. Southern to merge their production sites into one facility in Gateshead. With the full project taking less than a year, the move was completed by December 2019, including the relocation of over 4,000m3 of stock. We became involved in the project in June 2019, and finished on site in September 2019, following the installation of an 11kV, 500KVA, substation with a single point, low voltage, 800 amp supply to the sawmill. We collaborated with the client to understand the historical energy usage and proposed an INDO adopted solution, significantly reducing their connection costs., as well as cutting the project timescale from 7 to 3 months.

The site was operational during the build of a new production facility and sawmill, creation of fully covered storage space and the installation of new preservative treatment tanks. We enabled this to happen through the provision of an alternative feed throughout the works.

We’re proud to have contributed to the smooth running of the business throughout the project. Delivering a connection on time and on budget was crucial to the client’s requirements to ensure they could meet customer orders, and we’re pleased to have supported another UK business in achieving their goals.

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Since 2004, Air Liquide has provided bulk gases to the manufacturing, pharmaceutical, food and beverage industries. They recently moved their UK production plant to the Midlands, so their existing manufacturing facility required an increased power supply. Green Frog Connect successfully installed a new 20MW 132kV connection, enabling the business-critical factory upgrade to go ahead.

Location: Birmingham
Client: Air Liquide
Services: ICP, Engineering, Procurement, and Construction services, Customer balance of plant construction and commissioning.

Project details

Bounded tightly by a railway line, existing on-site industrial operations and a working car park, the site for our latest HV installation presented our project team with some interesting challenges. From contract award successful energisation was achieved within the targeted twelve months program.

Once work began on site, several unexpected and unmarked and significant Victorian culverts were discovered running beneath the planned cable route and throughout the client’s site which created additional design challenges. Local network fault levels also presented the opportunity for an innovative earth design solution to mitigate against any resultant imported Hot Zone contours across the adjacent Network Rail track. Our technological approach prevented what would otherwise traditionally have required a disruptive redesign of the client’s site and a significant impact on the overall project delivery.

Throughout the project it was vital that existing production services were able to continue as normal. Our team led the complex logistics required to ensure our client experienced no operational impact from our works. We liaised with all other parties working across the clients site build to ensure all works dovetailed seamlessly with each other to ensure completion ahead of the client’s scheduled on-site plant commissioning.

We’re delighted to have played a central part in delivering this 132kV connection which enabled the upgrade of their manufacturing facility.

Click here to watch the site develop on Youtube.

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The existing DNO metering substation supplying the factory required a generator constrain panel for the solar farm which was located some two kilometres away. Our challenge was to find a reliable solution to transfer the constraint signals to the solar park.

Our solution was to use a fibre cable, complete with programable converters, to transform the hardwired volt free contacts via the ethernet. Due to tight client deadlines, and typical manufacturer availability, we designed and built the required panels mirroring each other at the remote ends. A built-in watchdog for continuous monitoring ensured any failure in communication would curtail generation and avoid tripping of any existing factory supplies. Each panel is built with an integrated supply unit with battery support should external supplies fail.

The post Rising to the challenge appeared first on Green Frog Connect.

Click here to watch the site develop on Youtube.

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